Process for manufacturing shaped forms of packaging

ABSTRACT

Process for manufacturing cold formed shaped forms of packaging having at least one recess from a metal-plastic laminate. Examples of such shaped forms of packaging are the base parts of push-through packs or blister packs. The process is such that the laminate is held between a retaining tool and a die. The die  1  exhibits at least one opening and a stamp is driven into the die opening causing the laminate to be shape-formed into a packaging, correspondingly exhibiting one or more recesses. 
     The die and the retaining tool exhibit facing edge regions and the die, within the edge region, exhibits a shoulder region that surrounds the die opening or openings. The surface of the shoulder region lies 0.01 to 10 mm lower than the surface of the edge region of the die, and a first stamp or first stamps with high friction forming surface form the metal-plastic laminate in one or more steps down to 100% of the final depth of the recess and subsequently a second stamp or stamps with low friction forming surface perform the final forming of the laminate in one or more steps to at least 100% of the final depth of the recess.

This is a Division, of application Ser. No. 08/755,215, filed Nov. 22,1996, now U.S. Pat. No. 5,879,612.

BACKGROUND OF THE INVENTION

The present invention relates to a process for manufacturing cold-formedshaped forms of packaging from a metal-plastic laminate in which thelaminate is held between a retaining tool and a die exhibiting at leastone opening, and a stamp is driven into the die opening causing thelaminate to be formed into a shaped form of packaging featuring one ormore recesses. The present invention relates also to a device forperforming the process of cold forming a metal-plastic laminate into ashaped form of packaging.

It is known to manufacture shaped forms of packaging such as e.g. baseparts for blister packs, also known as push-through packs, or otherforms of packaging e.g. by deep drawing, stretch-drawing orthermoforming. The shaped packaging may be manufactured fromthermoplastics or from composites or laminates such as e.g. aluminumfoils and plastic films or extruded layers of thermoplastics.

If the packaging is made of laminates containing metal foils, thenshaping tools comprising a stamp, a die and a retaining tool may beemployed for its manufacture. As it is being deformed, the laminate isclamped securely between the die and the retaining tool, and the stampmoved towards the laminate. As it is lowered, the stamp moves deeperinto the openings in the die thereby deforming the laminate. In thatprocess the flat laminate is converted into a shaped part exhibiting oneor more recesses which are surrounded by shoulders corresponding to theoriginal flat plane of the laminate. Only that part of the laminate inthe region of the die opening can flow or be stretched to form a shapedpart. Adequate lateral distance must be maintained between the stamp andthe die opening in order that the laminate, especially laminatescontaining metal foil, can be deformed without cracks and pores forming.If the laminate contains a metal foil, only recesses of small sidewallheight can be achieved by this cold forming process. The result is poordrawing ratios i.e. shallow recesses of large diameter and, therefore,forms of packaging which are too large in relation to the contents.

One possibility for obtaining more laminate for shape-forming purposesmay be to reduce the retaining force and to employ deep drawing methods.However, folds would form in the edge or shoulder regions, and so thistype of technology may not be used e.g. for making blister packs fromlaminates containing metal foil. The edge region and, if desired, theshoulder region of shaped forms of packaging are normally employed forsealing on the lid. If there were folds present there, however, then itwould not be possible to seal the edge and shoulders.

SUMMARY OF THE INVENTION

The object of the present invention is to describe a process whichenables shaped forms of packaging, or shaped parts, to be made fromlaminates containing metal foil by means of cold forming whereby theforms of shaped packaging so produced are free of folds, and therecesses exhibit large wall height.

That objective is achieved by way of the invention in which a the dieand the retaining tool feature a facing edge region and the die, withinthe edge region, features a shoulder region that surrounds the dieopening or openings, and the surface of the shoulder region lies 0.1 to10 mm lower than the surface of the edge region of the die, and a firststamp or stamps, featuring a high friction, pre-forms the metal-plasticlaminate in one or more steps up to 100% of the final depth of therecess, and subsequently a second stamp or stamps, featuring a lowfriction forming surface forms the pre-formed metal-plastic laminate inone or more steps to at least 100% of the final depth of the recess.

In the present invention the various stamps are advantageously employedone after the other and, in a series of steps down maximum depth viapre-forming, each stamp is lowered into the die opening by the sameamount or further than the preceding stamp. As the metal-plasticlaminate springs back, at least the last forming step must exceed thefull, desired depth of deformation.

In a useful version of the invention the stamp is driven in a first stepor steps down to 90%, especially usefully to 70% and advantageously to50% of the final depth of the recess, and in a second step or steps isdriven down to 100-115%, advantageously 103-110% of the final depth ofthe recess.

Usefully, the stamps or stamping tools, which exhibit a high frictionforming surface and are employed in the first step or steps, arecylindrical, blunted cone, blunted pyramid or barrel shaped. The stampsemployed for the second step or steps have the shape of a cone, pyramid,blunted cone, blunted pyramid, segment of a sphere or cap. The stampsfor the first step feature in particular vertical or steep sidewalls,and the edge or periphery at the bottom of the stamp has a small radius.The lower friction surface stamp for the second step, may be vertical orless steep and in particular exhibit sloping sidewalls, and thetransition to the bottom of the stamp may be rounded or roundish inshape. This enables the metal-plastic laminate to slide only poorly overthe edge or periphery between the sidewall and bottom of the stamp sothat the metal-plastic laminate material from other regions is deformedfirst, then in a second step or steps, because of the low friction andthe rounded shape of the stamp, the metal-plastic laminate material fromthe bottom region of the stamp is also deformed.

In a second useful version the stamp with a high friction formingsurface in contact with the laminate may exhibit higher friction thanthe stamp with a low friction forming surface.

The process according to the invention be performed e.g. using a die andretaining tool and two or more stamps which are lowered one after theother into the openings in a die then raised again. On their surfacesthat effect forming the stamps or stamping tools exhibit differentdegrees of friction. For pre-forming a first stamp with high frictionforming surface is employed; this tool is then withdrawn and a secondstamp with low friction forming surface performs the final shape-formingin the same die. Likewise, one may employ three or more stamps withforming surfaces of two different degrees of friction or graduallysmaller degrees of friction.

The process may be advantageously performed in such a manner that thestamps are arranged coaxially or telescopically inside each other. Afirst stamp, featuring in particular a low friction forming surface andring-shaped in plan view, can effect pre-forming by lowering it into thedie. The first stamp may be left in the pre-forming position and asecond cylindrical-shaped stamp which slides telescopically in the firstring-shaped stamp and exhibits a high friction forming surface, is thenlowered effecting the final forming of the laminate. Such stamping toolsmay be made up of two or more ring-shaped stamping tools and aninnermost cylindrical stamping tool all of which slide telescopicallyinside each other. The degree of friction of the surfaces effectingforming may decrease gradually from a high degree of friction on theoutermost stamping tool to a low degree of friction on the innermoststamping tool, usefully at least in two steps.

The process may also be performed preferably in such a manner thatseveral dies, in particular two dies with their retaining tools, arearranged one after the other and with a stamp appointed to each die.Correspondingly, with two dies and their appointed stamps arranged oneafter each other, the surface of the first stamp that effects formingmay exhibit high friction, the second stamp low friction. Working at aset rhythm the laminate is pre-formed in a first step in the first die,then formed to the final shape in a second step in the second die. It isalso possible to perform the pre-forming in two or more steps and todivide the final shaping operation into two or more steps, with theresult that the total number of steps in the process used is three, fouretc., etc., whereby the friction may be reduced in two steps orgradually in the course of the individual steps.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 to 9 explain the present invention in greater detail by way ofexample.

FIG. 1 shows in cross-section a device for manufacturing cold-formedblister packs according to the current state of the art;

FIGS. 2 and 3 show schematically in cross-section a device according tothe invention in the two sequential steps of the process;

FIG. 4 shows in plan view a die for the device according to the presentinvention;

FIG. 5 represents a plan view of a retaining tool for the deviceaccording to the invention;

FIG. 6 shows schematically a step in the process according to theinvention;

FIGS. 7 and 8 show schematically a version of the device according tothe invention in the two sequential steps of the process; and

FIG. 9 shows a cross-section through a stamping tool.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The recesses formed out of the area of laminate material may becup-shaped, dish-shaped, cap-shaped, barrel-shaped, cylindrical etc. Asviewed in plan view, the recesses may be round, oval or polygonal, suchas two, three, four, or more cornered. Preferred are recesses with steepto vertical sidewalls which are as straight as possible and bases whichare domed as little as possible. The recesses are surrounded by a,normally flat, shoulder area of laminate material.

The preferred form of die is such that the surface area of the shoulderregion of the die lies 0.1 to 2 mm, preferably 0.15 to 0.3 mm lower thanthe surface of the edge region of the die.

The device according to the present invention may contain a die with oneor more openings.

Usefully, the device, and therefore the die, exhibits 1 to 200 dieopenings, preferably 8 to 40 die openings. The deformation of themetal-plastic laminate is effected by a stamp, which may as suchpenetrate a die opening. If the die features several openings, then thestamp may exhibit a support or support plate or holder plate or the likewith a corresponding number of stamping tools attached to it. The stampsor stamping tools are dimensioned in such a manner that that they canpenetrate the die openings while shape-forming the metal-plasticlaminate. Usefully, the diameter of the stamp or the stamping tool is 3to 35% smaller than the diameter of the related die opening, preferably1 to 15% smaller and in particular 5 to 10% smaller. By the diameter ofthe stamp or stamping tool or die opening in the case of a non-circularcross-section, such as a convex cross-section e.g. elliptic, oval,polygonal, rectangular, trapezium or rhomboid shaped etc., is meant thesmallest diameter.

As a rule, the walls of the openings in the die stand at an angle of 90°to the surface of the shoulder region. The edges that the wall of theopening and the surface of the shoulder region form with each other maybe rounded, with a radius e.g. of 0.1 to 10 mm, usefully 0.1 to 1 mm.

In another preferred version the edge regions of the retaining tool andthe die are each from 1 to 100 mm wide, usefully 2 to 30 mm andpreferably from 3 to 20 mm.

The die exhibits an edge region and within this edge region the shoulderregion. The die openings are arranged in particular symmetrically oralso asymmetrically within the shoulder region with the shoulder regionforming struts that surround the die openings.

The shoulder region of the die exhibits distances of 1 to 50 mm,preferably 5 to 25 mm between the edge region of the die and the dieopenings and between the individual openings.

The edge region of the retaining tool or the edge region of the die, orthe edge regions of the die and the retaining tool, may exhibit aroughness pattern over part or the whole of the surface there. Typicalroughness patterns are corrugations, waffle patterns, embossed patterns,honeycomb patterns, knobs, tooth-like patterns, roughened surfaces etc.Instead of or in addition to the roughness pattern, peripheral stripse.g. of an elastic material such as rubber and the like may be employed.In the working position the edge regions of the retaining tool and thedie usefully lie together over the metal-plastic laminate and, ifdesired with the support of the roughness pattern, hold the laminate inplace such that it cannot be stretched. The shoulder region of the dieusefully lies a distance from the parts of the retaining tool facing it;in this region the metal-plastic laminate does not make contact with theretaining tool, and the metal-plastic laminate can be stretched or flowaccording to the degree to which the stamp is lowered.

The shoulder regions of the die may be covered wholly or partly with alayer that, at least on the surface, exhibits a low degree of friction.A low degree of friction here means friction values of 0.2 to 2.1(dimensionless number), as measured according to method 311A in BritishStandard 2782. The low friction layer may e.g. contain or be of plasticssuch as polytetrafluorethylene, polyoxymethylene (polyacetal POM),polyethylene or polyethyleneterephthalate. The low friction layer mayalso exhibit in mixture form two or more of the plastics mentioned byway of example or one or more of the plastics in mixture form along withhard substances in divided form such as glasses in spherical form.Instead of plastics, other materials may be considered for the lowfriction layer. This means, for example, metals such as aluminum orchromium steel, especially with polished surfaces. Other low frictionlayers such as ceramic layers or layers containing graphite, boronnitride or molybdenum disulphide may be employed. The thickness of thelow friction layer on the shoulder of the die is not critical as onlythe surface is of consequence. Under industrial conditions the layer issubjected to large demands with regard to frictional forces and sopreference should be given to a thickness that permits some degree ofmaterial loss. For that reason the thickness of layer of the abovementioned plastics may be e.g. from 0.5 to 20 mm. The layer of plasticmay be inserted in the lowered region of the die as a preform, or it maybe deposited by spraying, brushing, wiping or some other method ofdeposition. The plastics may also be deposited for example in a matrixof other materials such as ceramic or metal using chemical methods orphysical methods such as electroplating or electrolytic deposition,plating or vapor deposition in vacuum, or the die may be made, at leastin part, of the metals in question.

As a rule, high friction stamps and low friction stamps, both withsurfaces effecting forming, comprise a retaining device such as aretainer plate and a number of stamping tools. The number of stampingtools usefully corresponds to the number of die openings. The stampingtools penetrate the openings in the retaining tool and the openings inthe die.

In the case of stamp with high friction surfaces effecting forming, atleast the surface effecting forming, i.e. the surface of the stamp orthe stamping tools coming into contact with the laminate, exhibits ahigh degree of friction. By a high degree of friction in the presentcase is meant friction values, according to method 311A, BritishStandard 2782, of e.g. 1.0 to 3.0 (dimensionless numbers). The highfriction surface may contain or be e.g. of metals such as steel, orplastics such as polyacetal (POM), polyethylene, rubber, hard rubber orcaoutchouc, including acrylic polymers. Using treatments such asroughening, a metal surface may be endowed with the properties producinghigh friction behavior.

In the case of stamps with low friction forming surfaces, at least thesurface effecting forming, i.e. the surface of the stamp or the stampingtools coming into contact with the laminate, exhibits a low degree offriction. By a low degree of friction in the present case is meantfriction values, according to method 311A, British Standard 2782, ofe.g. 0.3 or less to 2.1 (dimensionless numbers). The low frictionsurface may contain or be e.g. of metals such as steel, or plastics suchas polytetrafluorethylene, polyoxymethylene (polyacetal, POM),polyethylene, polyethylene-terephthalate. The low friction layer mayalso exhibit in mixture form two or more of the plastics mentioned byway of example or one or more of the plastics in mixture form and,additionally in divided form, hard substances such as glasses inspherical form. Instead of plastics, other materials may be consideredfor the low friction layer. This means, for example, metals such asaluminum or chromium steel, especially such with polished surfaces.Other low friction layers such as ceramic layers or layers containinggraphite, boron nitride or molybdenum disulphide may be employed.

In using the process according to the present invention the highfriction stamp or stamping tools advantageously exhibit a higherfriction value or higher friction values than the friction value orvalues of the low friction stamp.

Metal-plastic laminates that may be used are e.g. laminates containing ametal foil which is 8 to 150 μm thick, preferably 20 to 80 μm thick. Thefoil may be e.g. of steel, iron, copper and preferably aluminum.Included are also metal foils of alloys containing mainly one of theabove mentioned metals. Preferred aluminum foils may e.g. be aluminumhaving a purity of at least 98.0%, usefully 98.3%, advantageously 98.5%and especially 98.6%, the remainder making up the 100% being theaccompanying impurities. Further, aluminum foils e.g. of the type AlFeSior of the AlFeSiMn type may be employed.

The plastics used may be e.g. layers, films or laminates, whereby thefilms and laminates may also be uniaxially or biaxially stretched, be ofthermoplastics of the polyolefin, polyester, polyvinylchloride type andother types.

Typical examples of thermoplastics of the polyolefin type arepolyethylenes such as MDPE, HDPE, uniaxially, or biaxially stretchedpolypropylenes, polypropylenes such as cast polypropylene and uniaxiallyor biaxially stretched polypropylenes or polyethyleneterephthalate fromthe polyester series.

The thickness of the thermoplastic, whether as layer, film or laminatein the metal-plastic laminates may be e.g. 12 to 100 μm, preferably 20to 60 μm.

The metal foils and thermoplastics may be converted into a laminate e.g.by adhesive bonding, calandering or extrusion adhesive bonding. To jointhe layers, adhesives and bonding agents may be applied as required andthe surfaces to be joined may be modified by a pre-treatment involvingplasma, corona or flame treatment methods.

Examples of metal-plastic laminates are those having a first layer e.g.a film or a film-laminate of the above mentioned thermoplastics, asecond layer in the form of a metal foil and, on the free side of themetal foil, a third layer viz., a sealing layer of a polyolefin such aspolyethylene or polypropylene or PVC.

Further useable metal-plastic laminates may exhibit a first layer e.g. afilm or film-laminate of the above mentioned thermoplastics, a secondlayer in the form of a metal foil, and a third layer, for example a filmor film-laminate or an extruded layer out of one of the above mentionedthermoplastics. Further layers such as sealing layers may be provided.

The metal-plastic laminates may feature a sealing layer in the form of asealable film or a sealable coating at least on one of the outer lyingsides, or on both outer sides. The sealing layer is of necessity theoutermost layer in the laminate. In particular the sealing layer may beon one outer side of the laminate, and should be directed towards thecontents or shoulder side of the shaped packaging, this in order toenable the lidding foil or the like to be sealed into place.

Typical examples of metal-plastic laminates used in practice are:

oPA 25/Al 45/PVC 60

oPA 25/Al 45/oPA 25

Al 120/PP 50

oPA 25/Al 60/PE 50

oPA 25/Al 60/PP 60

oPA 25/Al 45/PVC 100

oPA 25/Al 60/PVC 60

oPA 25/Al 45/PE coated

oPA 25/Al 45/cPA 25

oPA 25/Al 60/PVC 100 and

oPA 25/Al 60/oPA 25/EAA 50

where oPa stands for oriented polyamide, cPA for cast polyamide, PVC forpolyvinylchloride, PE for polyethylene, PP for polypropylene, EAA forethylene-acrylic acid and Al for aluminum and the numbers the thicknessof the layer or foil in μm.

The present invention relates also to the device for performing theprocess according to the invention in which the die and the retainingtool exhibit facing edge regions which clamp the laminate between theedge of the die and the edge of the retaining tool such that it cannotstretch, and the stamping tools which draw the laminate over theshoulders of the die into the die openings which lie within a shoulderregion in the die, the surface of the shoulder region lying 0.01 to 10mm lower than the edge region of the die, and the laminate slides orflows as it is drawn or stretched over the surface of the shoulderregion.

Useful is a device for performing the process in which the surface ofthe shoulder region of the die lies 0.1 to 2.0 mm, preferably 0.15 to0.3 mm lower than the surface of the edge region of the die.

Preferred is a device for performing the process according to theinvention in which the shoulder regions of the die are partially orwholly covered with a surface layer exhibiting a low friction value of0.3 to 2.1.

Preferred is also a device for performing the process according to theinvention featuring at least one stamp with a high friction formingsurface and at least one stamping tool with a low friction formingsurface.

Also preferred is a device for performing the process according to theinvention in which the high friction forming surface is of steel,polyacetal (POM), rubber, caoutchouc or acrylic caoutchouc.

Also preferred is a device for performing the process according to theinvention in which the low friction forming surface is of steel,polytetrafluorethylene, polyoxymethylene polyethylene orpolyethyleneterephthalate.

The present invention relates also to cold formed shaped packagingmanufactured by the process according to the invention in which theshaped packaging is a metal-plastic laminate containing

oPA 25/Al 45/PVC 60 or

oPA 25/Al 45/oPA 25 or

Al 120/PP 50 or

oPA 25/Al 60/PE 50 or

oPA 25/Al 60/PP 60 or

oPA 25/Al 45/PVC 100 or

oPA 25/Al 60/PVC 60 or

oPA 25/Al 45/PE coated or

oPA 25/Al 45/cPA 25 or

oPA 25/Al 60/PVC 100 or

oPA 25/Al 60/oPA 25/EAA 50

where oPa stands for oriented polyamide, cPA for cast polyamide, PVC forpolyvinylchloride, PE for polyethylene, PP for polypropylene, EAA forethylene-acrylic acid and Al for aluminum and the numbers the thicknessof the layer or foil in μm.

Within the scope of the invention is the use of shaped packaging formswhich have been cold formed by the process according to the invention,as a container for accommodating individual items in the recesses.Examples of such items are e.g. one, two or three tablets, dragées,pills, ampoules etc. in each recess of a shaped form of packaging suchas a blister pack or push-through pack.

The device according to the invention may be employed for manufacturingcold formed shaped packaging forms such as blister packs forpharmaceuticals, foodstuffs and luxury consumables, technical articles,for base and lid parts of semi-rigid and rigid packaging, for enclosingpurposes etc. out of metal-plastic laminates.

When thermoforming plastic films such as e.g. PVC into blister packs itis possible to achieve high sidewalls. Up to now it has not beenpossible to achieve such high sidewalls on the recesses of shaped formsof packaging such as blister packs made from laminates containing metalfoils. This meant that the form of packaging that had to be used wasmuch too large in comparison with the contents. It is now possible usingthe present process to produce shaped forms of packaging that do notexhibit the disadvantages experienced to date i.e. such as the low wallheight compared to that achieved with thermoformed plastic films. Withthe present process it is now possible to manufacture shaped forms ofpackaging which with respect to size of packaging, are at leastcomparable, if not better compared e.g. with plastic blisters. Thepackaging can therefore be designed to look more attractive and to havea better image from the ecological standpoint.

A drawing ratio, i.e. a ratio of diameter to the height of the recessformed, of e.g. 2 to 3 may be achieved. The diameter of the recess, ifnot round in cross-section, is to be understood as the smallest diameteri.e. in the case of non-circular cross-sections, such as a convexcross-section e.g. elliptical, oval, polygonal, rectangular, trapeziumshaped, rhomboid etc.

The largest diameter of individual recesses may be e.g. 1 to 500 mm,preferably 3 to 30 mm, and the height of a recess from 1 to 100 mm,preferably 3 to 30 mm.

The number of recesses in the base part is not critical and may e.g. beone, two or more. In pharmaceutical applications packs with 6 to 40recesses are normal.

By cold forming is meant here forming at temperatures of e.g. 10 to 35°C., preferably 20 to 30° C.

The laminates that are processed into shaped forms of packaging such asblister packs and in particular base parts of blister packs remainpore-free even at high drawing ratios, and the reject rate due toforming is substantially reduced.

Seen in FIG. 1 is a state-of-the-art device comprising a die 1 aretaining tool 5 and a stamp 6. In the present case the stamp features asupport (not shown) and mounted thereon a number of stamping tools 6.The number of stamping tools corresponds to the number of openings inthe die 1. The stamps or the stamping tools 6 penetrate the opening 7 inthe retaining tool. A metal-plastic laminate 20 is placed between thedie 1 and the retaining tool 5. By applying force, the retaining tool 5is pressed against the die 1, as a result of which the metal-plasticlaminate 20 is held securely at all places of contact between the die 1and the retaining tool 5, essentially unable to be stretched. Thestamping tools 6 are lowered under the application of force and enterthe openings 7 in the retaining tool, press against the metal-plasticlaminate 20 and, while deforming the metal-plastic laminate 20, passthrough the die openings 8 in the die, until the desired degree ofdeformation of the metal-plastic laminate has been achieved.

The metal-plastic laminate is held both in the edge region and in theshoulder region 13 between the retaining tool 5 and the die 1,essentially unable to be stretched, and the deformation of the laminateeffected solely within the metal-plastic laminate material covering thedie opening 8.

In FIGS. 2 and 3 the process according to the invention is shown in twostages; the device, illustrated here in cross-section, shows the die 1,the retaining tool 5 and the stamps (stamping tools) 6. The retainingtool 5 features an edge region 12; also the die 1 features an edgeregion 11. A roughness pattern 9 is provided in the edge region 11 ofthe die. The whole shoulder region 13 i.e. the region of the die 1 thatis located within the die region 11 and forms the shoulders thatsurround the die openings, is lower than the edge region 11 of the die1.

A layer 3 is provided in the shoulder region 13 of the die 1, and isshown shaded in FIGS. 2 and 3. Layer 3 is a layer of a low frictionmaterial such as e.g. polytetrafluorethylene, polyoxymethylene,polyolefins or polyethyleneterephthalate etc. Advantageously, layer 3extends over the whole shoulder region 13 of the die 1. A layer 3 whichonly covers part of the shoulder region 13 is possible in some cases.

Lowering the shoulder region 13 of the die 1 may be achieved by achip-forming process such as milling, grinding or spark erosion etc. Thedie 1 may also be in two parts such that the edge region 11 and theshoulder region 13 can be moved and adjusted with respect to each otherand, on reaching the desired difference in height, may be secured inplace with respect to each other. The die 1 may also be a casting thatalready exhibits the lower height in the shoulder region 13. Likewise,it is also conceivable for the retaining tool 5 not to exhibit a flatsurface facing the die 1, but an edge region 12 and a shoulder regionthat is lower than the edge region 12.

The metal-plastic laminate 20 is shape-formed in the device according tothe invention. The metal-plastic laminate 20 may be introduced into thedevice in the form of an endless strip from a supply roll or in sheetform. The different parts of the metal-plastic laminate that undergodifferent degrees of deformation are indicated by 20′ 20″ and 20′″. Themetal-plastic laminate 20 is positioned, clamped between the retainingtool 5 and the die 1 and, especially in region 11 of the die 1 which iscovered by the edge region of the retaining tool 5, is unable to bestretched. The stamping tools are lowered under the application of forcethrough the openings 7 in the retaining tool, and press against themetal-plastic laminate 20″. While deforming the metal-plastic laminate,the stamping tools 6 are lowered through the openings 8 in the die untilthe desired degree of deformation of the metal-plastic laminate has beenreached. The metal-plastic laminate 20′″ in the whole of the shoulderregion 13 i.e. along the edge regions and the shoulders between the dieopenings 8, is able to flow and is deformed by stretching according tothe extent to which the stamp 6 is lowered into the die openings 8. Inaddition, the metal-plastic laminate 20″ between the shoulder region andthe stamping tool 6 is deformed by stretching. The stamping tools 6 havea surface exhibiting a high degree of friction and are to advantagecylindrical or barrel shaped. This means that the periphery or edgesbetween the base and sidewall of the stamping tool are of small radiusand the sidewall of the stamp form a steep angle or is vertical to thebase of the stamp. The deformation is performed until e.g. 100% of thefinal depth of the recess has been reached.

The second stage in the process according to the invention is shown inFIG. 3. There is no essential difference with respect to the die 1,retaining tool 5, openings 7 and 8, the roughness pattern 9, the edgeregion 11, the edge region 12 and the shoulder region 13 as far as thedevice is concerned. In the second stage of the process other stampingtools 6 are lowered into the die openings 8 thus deforming themetal-plastic laminate 20 further until the desired degree ofdeformation of the laminate has been achieved. The metal-plasticlaminate 20′″ can flow and be stretched further in the whole of theshoulder region 13 i.e. along the edge regions and the shoulders betweenthe die openings 8 and to an extent according to the amount to which thestamping tools 6 are lowered into the die openings 8. Also themetal-plastic laminate 20′ between the shoulder region and the stampingtool body 6 is stretch-formed further. A stamping tool with e.g. a body6 of blunted cone cross-section is employed for the second stage of theprocess. The surface of the stamping tool body 6 effecting formingexhibits low friction. Consequently, the metal-plastic laminate 20″ inthe region of the surface of the stamping tool effecting forming is alsoable to flow. The forming operation is performed e.g. at least until thefinal depth of the recess has been reached i.e. at least to 100% of therequired depth.

FIG. 4, a plan view of a die 1, shows the edge region 11 and theshoulder region 13. The edge region 11 may feature a roughness pattern9. The shoulder region 13 lies 0.01 to 10 mm lower than the edge region11. In an advantageous version the shoulder region 13, is partly andespecially fully covered with the described low friction deposit orlayer 3. The die openings 8 are shown by way of example in a regulararray in the shoulder region 13. As a rule these are holes i.e. openingsor recesses that are round in cross-section or openings that are oval incross-section. Also openings that are polygonal in cross-section e.g.rectangular, square or six sided may be created without any difficulty.

A retaining tool 5 is shown in plan view in FIG. 5. The surface 14 ofthe retaining tool 5 which faces the die and comes to rest on thelaminate during manufacture may be flat. In the production stage thelaminate is securely clamped across the areas of contact with the edgeregion 12 of the retaining tool 5 and the edge region 11 of the die 1,and viz., such that the laminate can not stretch or flow there. Insteadof a flat surface the retaining tool 5 may also feature an edge region12 and lower region within the edge region, or the retaining tool 5 mayessentially comprise only of the edge region i.e. a ring. A roughnesspattern may be provided over part or the whole of the surface in theedge region 12 of the retaining tool 5. The edge region of the retainingtool 5 is usefully positioned and essentially of the same dimension asthe edge region 11 of the die 1.

The retaining tool 5 exhibits a plurality of openings 7 or recesses, inthe present case openings. The openings 7 are penetrated by the stampsor stamping tools and, accordingly, the holes are arranged in the samemanner and at least approximately the same size as the openings 8 in thedie 1.

The lines II—II in FIG. 4 and III—III in FIG. 5 are the lines ofcross-section through the die 1 and retaining tool 5 shown in FIGS. 2and 3.

The process according to the present invention is shown simplified andschematically in FIG. 6. A metal-plastic laminate 20 is uncoiled from aroll 23 and fed to a first stamp with body 6′ then to a second stampwith body 6″. Recesses are thereby pressed into the metal-plasticlaminate 20 in two stages. The result is a shaped form of packaging towhich the contents 22 are then added. Thereafter, a lidding foil 21 maybe continuously uncoiled from a roll 24 and sealed or the like onto theshaped packaging. The endless packaging strips can then be cut to thedesired pack sizes.

Shown in FIGS. 7 and 8 is a further version of the process according tothe invention taking place in two stages, the device, illustrated incross-section, showing the die 1, the retaining tool 5 and the stamp 6.Further details and their notation being as shown in FIGS. 2 and 3. Alayer 3 is provided in the shoulder region 13 of the die 1. The layer 3is shown shaded and is the layer of low friction material, known fromFIGS. 2 and 3. FIG. 7 shows the first step in the process. Themetal-plastic laminate 20 is being shape-formed by the stamps 6 whichmake up a unit and are in e.g. two parts. A hollow, cylindrical stamp25, which in plan view is ring-shaped and has a high friction formingsurface, is lowered and pre-forms the metal-plastic laminate 20. Asshown in FIG. 8, the final shape-forming of the metal-plastic laminate20 takes place in the second stage. A cylindrical stamp 26 slidestelescopically inside stamp 25 which in FIG. 7 has reached its lower endposition where it remains. The stamp 26 slides telescopically out ofstamp 25 and is lowered beyond stamp 25. As a result, the stamp 26 withits low friction forming surface deforms the metal-plastic laminate 20advantageously up to and beyond the desired 100% depth of formation.

FIG. 9 shows a single piece stamp 6 made up of materials 27, 28, 29 withdifferent coefficients of friction. Accordingly, shape-forming surface30 of the stamp 6 exhibits higher coefficient of friction thanshape-forming surface 31 and, in turn, shape-forming surface 32 exhibitsa lower coefficient of friction than surface 31.

In the present example a relatively small die is shown. It is alsopossible to design dies according to the present invention with theshoulder region subdivided by transverse and/or longitudinal struts. Themetal-plastic laminate is held, clamped securely in place, in the regionof these struts. This enables a plurality of shaped packaging to beproduced e.g. with one die and one stroke of the stamp. After theshaping process, the shaped packs that are produced simultaneously maybe separated e.g. at dividing lines along the struts.

What is claimed is:
 1. Cold-formed shaped packaging which comprises ashaped packaging made of a metal-plastic laminate with at least onepackaging recess therein, said at least one recess having a diameter anda height wherein a ratio of diameter to height of said at least onerecess is 2-3, and a substantially flat foil lidding sealed onto theshaped packaging wherein said shaped packaging is free of folds.
 2. Coldformed shaped packaging according to claim 1, characterized in that theshaped packaging is made of a metal-plastic laminate containing in itsmake up oPA 25/Al 45/PVC 60 or oPA 25/Al 120/PP 50 or oPA 25/Al 60/PE 50or oPA 25/Al 60/PP 60 or oPA 25/Al 45/PVC 100 or oPA 25/Al 60/PVC 60 oroPA 25/Al 45/PE coated or oPA 25/Al 45/cPA 25 or oPA 25/Al 60/PVC 100 oroPA 25/Al 60/oPA 25/EAA50 where oPA stands for oriented polyamide, cPAstands for cast polyamide, PVC stands for polyvinylchloride, PE standsfor polyethylene, PP stands for polypropylene, EAA stands forethylene-acrylic acid copolymer and Al stands for aluminum and thenumbers for the thickness of the layer or foil in μm.
 3. Cold formedshaped packaging according to claim 1, including a plurality of saidrecesses spaced from each other.
 4. Cold formed shaped packagingaccording to claim 3, wherein said recesses have a diameter of 1-500 mm.5. Cold formed shaped packaging according to claim 3, including 6-40 ofsaid recesses.
 6. Cold formed shaped packaging according to claim 1,wherein said metal-plastic laminate has a metal layer of 8-150 microns.7. Cold formed shaped packaging according to claim 6, wherein theplastic layer has a thickness of 12-120 microns.
 8. Cold formed shapedpackaging according to claim 1, wherein said metal-plastic laminate hasa central metal layer and plastic layers on either side thereof.